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E-TEC E40DPLSCB
Evinrude E-TEC E40DPLSCB User Manual
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Table of Contents
Default Chapter
4
Table of Contents
4
Introduction
5
Safety Information
6
Units of Measurement
8
Abbreviations Used in this Manual
8
List of Abbreviations
8
Introduction
8
Engine Emissions Information
9
Manufacturer's Responsibility
9
Dealer's Responsibility
9
Owner's Responsibility
9
Epa Emission Regulations
9
Model Designation
10
Models Covered in this Manual
11
Identifying Model and Serial Numbers
11
Service Specifications
12
Standard Torque Specifications
14
Product Reference and Illustrations
14
Special Tools
15
Diagnostic Tools View
16
Special Tools
16
Universal Tools View
16
Electrical/Ignition Tools View
18
Special Tools
18
Fuel /Oil System Tools
19
Powerhead Tools
19
Gearcase Tools
20
Manual Starter Tools
22
Trim and Tilt Tools
22
Shop Aids View
23
Notes
26
Installation and Predelivery
27
Boat Rigging
28
Control Selection
28
Remote Controls
28
Battery Installation
29
Control Installation
29
Location and Preparation
29
Minimum 12 Volt Battery Recommendations
29
Battery Cable Requirements
30
Battery Switches and Multiple Batteries
30
Connections
30
Installation and Predelivery
30
Marine Style Battery Post Diagram
30
Battery Switch Location
31
Battery Switch Operation
31
Battery Switch Requirements
31
Typical Battery Functions
31
Battery and Switch Wiring Diagrams
32
One Outboard: Battery Disconnect Diagram
32
One Outboard: One Primary Starting Battery; One Secondary Battery Diagram
32
Wo Outboards: Two Starting Batteries for each Outboard Diagram
32
Two Outboards: One Primary Starting Battery for each Outboard Diagram
33
Fuel Hose
34
Fuel System Primer
34
Fuel System Requirements
34
Fuel Filters
35
Outboard Fuel System Recommendations
35
Portable Fuel Tanks
35
Cable and Hose Installation
36
Cable and Wire Harness Routing
36
Typical Large Splash Well Diagram
36
Typical Small Splash Well Diagram
36
Battery Cables
37
Protective Sleeve/Conduit
37
Clamp Identification Numbers View
38
Oetiker Clamp Servicing
38
Oetiker Stainless Steel Stepless Clamps Table
38
Clamp Installation
39
Clamp Removal
39
Control Cable Identification
40
Hull Preparation
40
Mounting Surface
40
Outboard Installation
40
Mounting Hardware
41
Transom Brackets and Jack Plates
41
Transom Clearances
41
Water Flow
41
Dual-Outboard Centerlines
42
Hull Centerline
42
Transom Height
42
Transom Measuring and Drilling
42
Transom Drilling Locations
43
Drilling and Hardware Diagrams
44
Lifting Fixtures
46
Lifting the Outboard
46
Mechanical Cables
46
Steering Systems
46
Drag Links
47
Manual Hydraulic Steering
47
Mounting Bolt Installation
48
Mounting Height
48
Outboard Mounting
48
Cable, Hose, and Wire Routing
50
Control Cable Adjustments
50
Outboard Rigging
50
Cable Retainer Clip Installation
51
Locked Retainer Clip View
51
Electrical Harness Connections
52
Seal View
52
Water Pressure Gauge
52
Water Pressure Hose Fitting View
52
Canbus Connections
53
Additives
55
Fuel and Oil Priming
55
Fuel Requirements
55
Minimum Octane
55
Engine Lubricant below 32°F (0°C)
56
Fuel System Priming
56
Oil Requirements
56
Vent Line Clamp
56
Oil Injection Rate
57
XD100 Outboard Oil Decal View
57
Break-In Oiling
58
Oil Supply Priming
58
Before Start-Up
59
Gearcase Lubricant
59
Oil Level
59
Trim and Tilt Fluid
59
Emergency Stop / Key Switch
60
Engine Monitoring System
60
Fuel System Checks
60
Remote Control Operation
60
Running Checks
60
Start-In-Gear Prevention
60
Tachometer Pulse Setting
60
Break-In
61
Idle Speed
61
Operating Temperature
61
Water Pump Overboard Indicator
61
Propeller Selection
62
Propeller Hardware Installation
63
Final Adjustments
64
Trim Sending Unit Adjustment
64
Dual Outboards, One Counter and One Standard Rotation
65
Dual Standard Rotation Outboards
65
Outboards with High Transom Heights
65
Trim Tab Adjustment
65
Alignment Adjustment
66
Confirm Alignment
66
Dual-Outboard Alignment
66
Measure Alignment
66
Maintenance
67
Inspection and Maintenance Schedule
68
Anti-Corrosion Protection
69
Exterior Finishes
69
Metallic Component Protection
69
Sacrificial Anodes
69
Testing Procedure – Continuity
69
Cooling System Maintenance
70
Flushing — Outboard Not Running
70
Flushing — Outboard Running
70
Additional Maintenance
71
Lubrication
71
Steering System Lubrication
71
Water Intake Screens
71
Swivel Bracket and Trailering Bracket
72
Throttle and Shift Linkage
72
Tilt Tube
72
Gearcase Lubricant Draining
73
Gearcase Lubricant Inspection
73
Propeller Shaft Lubrication
73
Gearcase Lubricant Filling
74
Trim and Tilt Lubrication
75
Battery and Battery Connections
76
Fuel and Oil Systems
76
Fuel Filter
76
Oil Filters and Oil Reservoir
76
Air Silencer
77
Hoses and Connections
77
Spark Plugs Indexing
78
Spark Plugs Removal
78
Fuel System Treatment
79
Internal Engine Treatment
79
Storage
79
Throttle Control Method
79
Additional Recommendations
80
Battery(S)
80
Gearcase Lubricant
80
Operational Checks
80
Outboard Mounting Bolts
80
Power Trim and Tilt
80
Pre-Season Service
80
Engine Dropped Overboard (in Salt Water)
81
Prolonged Submersion (Fresh or Salt Water)
81
Submerged Engines
81
Notes
82
Engine Cover Service
83
Latch Hook Installation
84
Lower Cover Removal
84
Lower Cover Service
84
Upper Cover Service
84
Lower Cover Installation
85
Engine Cover Service
86
Latch Handle Installation
86
Trim Switch Installation
86
Engine Maintenance Module (EMM)
87
EMM Connections
88
EMM Functions
88
Engine Maintenance Module (EMM) Description
88
LED Indicators
88
EMM Inputs and Outputs Diagram
89
12 V Circuit Sensor
90
55 V Circuit Sensor
90
EMM Temperature Sensor
90
Engine Management Module (Emm)
90
Internal Sensors
90
Air Temperature Sensor
91
Barometric Pressure Sensor
91
External Sensors
91
Engine Temperature Sensor
92
Low Oil Switch
92
Throttle Position Sensor
92
Crankshaft Position Sensor
93
Neutral Switch
93
Idle Controller
94
Internal EMM Functions
94
Neutral RPM Limiter
94
ROM Verification
94
Engine Running
95
Service Mode
95
System Self-Test
95
The Engine Monitoring System
95
SAFE Warning System
96
Shutdown Mode
96
Communication
97
Diagnostic Software Functions
97
Static Information
97
Dynamic Information
98
Hard Faults, Persistent Faults
98
Static Tests
98
Stored Service Codes (Faults)
98
Dynamic Test Screen View
99
Fuel Pump Test
99
Ignition Test
99
Oil Injector Test
99
Oil Control Settings
100
Powerhead Break-In
100
Set Oil Type
100
Tiller/Remote Programming
100
Idle Speed Control
101
Ignition Timing
101
TPS Calibration
101
Fuel Injector Servicing
102
Reports
102
EMM Transfer
103
Software Replacement
103
EMM Servicing
104
System Analysis
105
Diagnostic Procedures
106
Operational Inspections
106
Visual Inspections
106
Outboard Cranks, will Not Start
107
Outboard Runs, Low on Power, Misfires
107
Outboard will Not Crank, Starter Does Not Operate
107
Troubleshooting
107
Cylinder Drop Tests
108
Dynamic Tests
108
Fuel Control Adjustment
108
Inductive Amp Meter Test
108
System Analysis
108
EMM LED Indicators
109
Key on
109
Starting
109
Running
110
Ignition Output Tests
111
Ignition System Requirements
111
Stator Output Voltage Test
111
Wiring Inspection
111
Crankshaft Position Sensor (CPS) Test
112
System Voltage Test
112
Static Ignition Test
113
Running Ignition Tests
114
Capacitor Test
115
Control Signal Test
115
Ignition Coil Tests
115
Ignition Control Circuit Tests
115
Fuel Delivery Tests
116
Fuel Injector Static Test
116
Fuel Pump Static Test
116
Running Fuel System Tests
117
Exhaust Water Valve Dynamic Test
118
Exhaust Water Valve Static Test
118
Electrical and Ignition
119
Electrical and Ignition: Service Chart
120
Dash Connections, Instrument Harness
122
Electrical and Ignition
122
Instrument Harness Diagram (MWS)
122
Elecrtical Harness Connections
123
EMM J1-A Connector
123
Engine Harness to Stator Connector
123
EMM J1-B Connector
124
EMM J2 Connector
124
Additional Ground Tests
125
EMM Ground Tests
125
Fuse
125
Ground Circuits
125
Sensor Tests
126
Throttle Position Sensor (TPS) Test
126
Air Temperature Sensor (AT) Test
127
Stator Resistance Tests
128
Stator Tests
128
Stator Voltage Output Test
128
Stator Winding Resistance Specification
128
12V Charging Circuit Test
129
Battery Charging Graph
129
Charging System Tests
129
Variable Load Test Diagram
129
55 V Alternator Circuit Test
130
Electric Start Circuit
131
Start Circuit Diagram
131
Engine Wire Harness
132
Instrument Wire Harness
132
Solenoid Wiring
132
Start Circuit Operation
132
Electric Start Tests
133
Key Switch, START Position
133
Starter Solenoid Test
133
No Load Current Draw Test
134
Key Switch Test
135
Neutral Start Circuit Test
135
Remote Control Switch Tests
135
Emergency Stop Switch Test
136
Neutral Start Switch Test
136
Tilt/Trim Relay Test
137
Exhaust Water Valve Test
138
Gauge Self-Test Check
138
Systemcheck Circuit Tests
138
Check Engine Circuit Test
139
LOW OIL Circuit Test
140
NO OIL Circuit
140
Water Temp/ Hot Circuit Test
140
Flywheel and Stator Servicing
141
Flywheel Removal
141
Tachometer Circuit Tests
141
Flywheel Installation
143
Stator Service
143
Timing Adjustments
144
Timing Pointer
144
Calibration of TPS
145
Timing Verification
145
Electric Starter Servicing
146
Starter Disassembly
146
Starter Removal
146
Starter Cleaning and Inspection
147
Starter Assembly
148
Connector Servicing
150
DEUTSCH Connectors
150
Starter Installation
150
Terminal Removal
150
AMP Connectors
151
Crimping Terminals
151
Terminal Installation
151
Packard Connectors
153
Fuel System
155
Service Chart - Injectors, Vapor Separator, Fuel Pump
156
Service Chart - Reed Plate Assembly and Throttle Body
157
Fuel System Hose Routing
158
Fuel System Circuit Diagram
159
Fuel Filter Info
160
Fuel Lift Pump
160
Fuel System Components
160
Vapor Separator
160
Electrical Circuit
161
Fuel Circulation Pump
161
Fuel Reservoir
161
Fuel Supply
161
Fuel Flow Compensation
162
Fuel Injectors
162
Fuel Manifolds
162
Injector Fuel Supply
162
Fuel System Pressure Test
163
Fuel System Tests
163
Fuel Injector Pressure Test
164
Pressure Regulator Test
164
Vapor Separator Vent Check
164
Circulation Pump Resistance Test
165
Fuel Injector Resistance Test
165
Lift Pump Pressure Test
165
Lift Pump Vacuum Test
166
Anti-Siphon Valve Test
167
Lift Pump Diaphragm Test
167
Fuel Component Servicing
168
Relieving Fuel System Pressure
168
Fuel Filter Service
169
Fuel Lift Pump Service
169
Fuel Manifold Service
170
Vapor Separator Service
170
Fuel Injector Service
171
Crush Ring Replacement
172
Intake Manifold Service
174
Oiling System
177
Oiling System Service Chart
178
Oil Supply Diagrams
179
Oil Recirculation Diagram
180
Oiling System
180
Oiling System Circuit Diagram
181
Electrical Circuit (55 V)
182
Oil Injection Pump
182
Oil Tank Assembly
182
Oiling System Components
182
Cylinder and Crankcase
183
LOW OIL Warning
183
NO OIL Warning
183
Oil Control Settings Info
184
Oil Priming
184
Oil Recirculation System
184
Oiling Rates, Break-In Oiling
184
Oil Injection Pump Voltage Test
185
Oiling System Tests
185
Oil Injection Pump Circuit Resistance Test
186
Oil Injection Pump Function Test
186
LOW OIL Sending Unit Test
187
Oil Injection Fittings Flow Test
187
Oil Component Servicing
188
Oil Distribution Hoses
188
Oil Tank Assembly Installation
189
Oil Tank Assembly Removal
189
Notes
190
Cooling System
191
Cooling System: Hose Routing and Water Flow Diagrams
192
Cooling System Components
193
Exhaust Housing
193
Pressure Relief Valve
193
Water Pump and Intakes
193
Block Venting
194
Cooling System
194
Thermostat
194
Water Pressure Connection
194
Cooling System Operation
195
Cylinder Block / Cylinder Head Cooling
195
EMM and Vapor Separator Cooling
195
Engine Temperature Check
196
Pyrometer Method
196
Software Method
196
Idle Operating Temperature Troubleshooting (below Range)
197
Thermostat Inspection
197
Assembly
198
Disassembly
198
Inspection
198
Thermostat Servicing
198
Assembly
199
Disassembly
199
Inspection
199
Pressure Relief Valve Servicing
199
Notes
200
Powerhead
201
Powerhead Service Chart
202
Powerhead Removal
204
Powerhead Removal (Rope Start Models)
205
General
206
Powerhead Disassembly
206
Shift Linkage Removal
206
Throttle Linkage Removal
206
Crankcase Disassembly
207
Connecting Rods and Pistons
208
Cylinder Head Removal
208
Crankshaft Removal
209
Cylinder Block Cleaning
212
Crankshaft Check
213
Cylinder Bore Check
213
Cylinder Head Check
213
Powerhead Inspection
213
Bearings Check
214
Piston Rings Check
214
Pistons Check
214
Bearings
215
Crankshaft Assembly
215
Powerhead Assembly
215
Pistons and Connecting Rods
217
Installing Pistons
218
Cylinder Head Installation
219
Crankshaft and Connecting Rod Installation
220
Crankcase Assembly
223
Shift Linkage Installation
225
Throttle Linkage Installation
225
Final Powerhead Assembly
226
Powerhead Installation
227
Powerhead Mounting
227
Shift Linkage Adjustment
229
Port Short Block View
230
Powerhead Views
230
Starboard Short Block View
230
Port Dressed Powerhead View
231
Starboard Dressed Powerhead View
231
Port Rope Start Models View
232
Starboard Rope Start Models View
232
Front View
233
Rear View
234
Top View
235
Top View, Rope Start Models
236
Midsection
237
Midsection Service Chart - Stern Bracket, Power Tilt Models
238
Midsection Service Chart - Stern Bracket, Manual Tilt Models
239
Exhaust Housing Diagram
240
11 Powerhead
240
10 Cooling System
240
Midsection
240
Tiller Handle (Long) Diagram
241
Tilt Tube Removal
242
Tilt Tube Service
242
Tilt Tube Installation
243
Exhaust Housing Removal
244
Exhaust Housing Service
244
Exhaust Relief Muffler
245
Exhaust Water Valve Servicing
245
Exhaust Housing Installation
246
Stern Bracket - Power Tilt Models
247
Stern Bracket Disassembly (Power Tilt)
247
Stern Bracket Assembly (Power Tilt)
248
Clamp Screw
249
Stern Bracket - Manual Tilt Models
249
Stern Bracket Disassembly (Manual Tilt)
249
Stern Bracket Assembly (Manual Tilt)
252
Tilt Assist Cylinder
255
Tiller Handle Removal
256
Tiller Handle Service - Standard
256
Tiller Handle Disassembly
257
Tiller Handle Assembly
258
Tiller Handle Inspection
258
Tiller Handle Installation
260
Throttle Cable Adjustment
261
Tiller Handle Removal
262
Tiller Handle Service - Long Handle
262
Tiller Handle Disassembly
263
Tiller Handle Inspection and Assembly
266
Installation
270
To Install the Tiller Handle
270
Control Cable Installation
271
Shift Cable Adjustment
271
To Adjust the Throttle Cable
272
Midsection and Tiller Adjustments
273
Steering Friction Adjustment
273
Throttle Friction Adjustment
273
Notes
274
Gearcase
275
Gearcase Service Chart
276
Gearcase Leak Test
277
Propeller Service
277
Gearcase Installation
278
Gearcase Removal and Installation
278
Water Pump Disassembly
280
Water Pump Inspection
280
Water Pump Service
280
Water Pump Assembly
281
Shift Rod Adjustment
282
Gearcase Disassembly
283
Pre-Disassembly Inspection
283
Propeller Shaft Bearing Housing Removal
284
Pinion Gear and Driveshaft Removal
285
Locked Driveshaft Removal
286
Shift Housing, Gear and Propeller Shaft Removal
286
Internal Gearcase Service
287
Pinion Bearing Installation
287
Pinion Bearing Removal
287
Water Intake Screen Check
287
Shift Housing Disassembly
288
Shift Housing Assembly
289
Driveshaft Bearing Housing Service
291
Bearing Removal
292
Propeller Shaft Bearing Housing Service
292
Rear Seal Removal
292
Bearing Installation
293
Rear Seal Installation
293
Driveshaft Shimming
294
Gearcase Assembly
295
Shift Housing, Gear, and Propeller Shaft Installation
295
Shift Rod Housing Installation
295
Pinion Gear and Driveshaft Installation
296
Propeller Shaft Bearing Housing and Gear Installation
298
Notes
300
Trim and Tilt
301
System Description
302
Trim and Tilt - System Inspection
302
Electrical Circuit Tests
303
General
303
Manual Release Valve
303
Relay Testing
303
Reservoir Fluid
303
Stern Brackets Inspection
303
Trim and Tilt - Routine Inspections
303
Trim and Tilt Motor Current Draw Tests
303
Trim and Tilt Motor no Load Test
304
Trim Gauge Test
305
Trim Sender Test
305
Trim and Tilt Disassembly
306
Trim and Tilt Removal
306
Trim and Tilt Servicing
306
Trim and Tilt Assembly
308
Trim and Tilt Installation
309
Adjustments
310
Manual Starter
311
Manual Starter Service Chart
312
Recoil Starter Disassembly
313
Recoil Starter Removal
313
Manual Starter
314
Recoil Starter Assembly
315
Recoil Starter Cleaning and Inspection
315
Recoil Starter Installation
319
Notes
320
Safety
321
Matine Products and the Safety of the People Who Use Them
323
Outboard Shift Systems and Safety
324
Outboard Speed Control System and Safety
325
Outboard Steering Control System and Safety
326
How Can Loss of Steering Control be Minimized
327
Transom Mounted Steering Systems – Check to Uncover Possible Trouble
327
How Can Fire and Explosion be Minimized
328
Outboard Fuel, Electrical System, and Safety
328
How Can Loss of Mounting be Minimized
331
Outboard Mounting System and Safety
331
If Weakened, Parts Could Fail Later on the Water, When Not Expected
332
Outboard Hydraulic Tilt/Trim Shock Absorption System and Safety
333
Outboard Emergency Stop System and Safety
334
How Can Failure of the Emergency Stop System be Minimized
335
Summing up
336
Handling Outboards
337
Marine Products and the Safety of People Who Fix Them
337
When Lifting Outboards
337
Outboard Starting at the Wrong Time
338
Running Outboard with Engine Cover Removed
338
Running Outboard too Fast (Overspeeding)
339
Running Outboards: Exhaust Fumes
339
Eye Protection
340
Running Outboards: Propellers
340
Charging Lead Acid Batteries
341
Handling Lead/Acid Batteries
341
Gasoline – Handle with Care
342
Hazardous Products
343
Safety Awareness Test
344
Index
345
Outboard will Not Start
353
Trouble Check Chart
353
Outboard Hard to Start
355
Outboard Starts and Stalls
356
Outboard will Not Shut off
356
Excessive Smoking
357
Outboard Starts, Low Maximum RPM
357
Outboard Surges, Runs Rough
358
Hose Routing and Water Flow Diagram - 40 – 65 E-TEC Inline 2 Cylinder
359
MWS Instrument Wiring Harness
360
Canbus Keyswitch/Tnt Wiring Harness
361
Lanyard Switch / Emergency Stop Circuits
362
MWS Key Switch and Neutral Safety Switch
363
MWS Dashboard
364
EMM LED Diagnostic Indicators
366
4
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Evinrude E-TEC E40DPLSCB Specifications
General
Brand
Evinrude
Model
E-TEC E40DPLSCB
Category
Outboard Motor
Language
English
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